Handle for a personal care implement and personal care implement

ABSTRACT

A handle for a personal care implement includes a connector for repeatedly attaching and detaching a head to and from the handle. The handle has a longitudinal extension extending between a proximal end closest to the head and a distal end opposite to the proximal end, the handle further having a core structure, the core structure and the connector being unitarily made to form a core-connector unit. A second component at least partially covers the core structure, wherein the core structure has a longitudinal extension extending along the longitudinal extension of the handle, the core structure comprising at least two protrusions interlocking with the second component.

FIELD OF THE INVENTION

The present disclosure is concerned with a handle for a personal careimplement, in particular with a handle for an oral care implement, thehandle comprising at least two different components and a connector forrepeatedly attaching and detaching a head to and from the handle. Thepresent disclosure is further concerned with a personal care implementcomprising such handle and a head.

BACKGROUND OF THE INVENTION

Heads and handles for oral care implements, like manual toothbrushes,are well known in the art. Generally, tufts of bristles for cleaningteeth are attached to a bristle carrier or mounting surface of a brushhead intended for insertion into a user's oral cavity. A handle isusually attached to the head, which handle is held by the user duringbrushing. Usually, heads of manual toothbrushes are permanentlyconnected to the handle, e.g. by injection molding the bristle carrier,the handle, and a neck connecting the head and the handle, in oneinjection molding step. After the usual lifetime of a toothbrush, i.e.after about three months of usage, the toothbrush is discarded. In orderto provide environmentally friendly/sustainable manual toothbrushesgenerating less waste when the brushes are worn out and discarded,manual toothbrushes are known comprising heads or head refills beingexchangeable, i.e. repeatedly attachable to and detachable from thehandle. Instead of buying a completely new toothbrush, consumers canre-use the handle and buy a new/fresh head refill only. Such refills areusually less expensive and generate less waste than a conventionalmanual toothbrush.

For example, manual toothbrushes are known comprising a handle to whicha replaceable head is connected. The handle is provided with a cavitywithin which the head is insertable. To provide a sufficiently strongconnection between the head and the handle, the brush head is formedwith a neck having a coupling anchor for engaging in a complementaryengaging mechanism within a collar of the handle.

In order to clean teeth effectively, appropriate maneuverability andgood handling properties of the overall toothbrush have to be provided,which properties, inter alia, depend on the center of gravity of thehandle/toothbrush, bending stiffness and weight of the handle, as wellas the brush head. Usually, handles of toothbrushes have the shape of alinear rod to be handled and manipulated by a user as needed. Sincemanual toothbrushes with replaceable brush heads comprise an innercavity within the handle portion to receive the replaceable head, it hasbeen seen that such handles are relatively light, and are, thus, neithercomfortable to handle nor easy to maneuver in the oral care cavity.Further, brushes comprising relatively light handles, e.g. handlescomprising less material, or handles being made of common plasticmaterials, e.g. polypropylene, lie less comfortably in the hand. Inorder to compensate said drawbacks, the size of the cross-sectional areaof the handle could be increased. However, relatively thick handles mayalso reduce ease of rotating the brush in the hand, thus, impeding theuser reaching all areas in the oral cavity. Further, it is known thatusers/consumers use different brushing techniques, and, therefore, it iscritical to identify optimal ergonomics of a toothbrush in order toprovide good sensory feeling during brushing when using all types ofbrushing techniques.

Further, personal care implements, in particular toothbrushes,comprising relatively light handles, e.g. handles being made of commonplastic materials, e.g. polypropylene, provide low product qualityperception during use of the implement.

It is an object of the present disclosure to provide a handle for apersonal care implement which overcomes at least one of theabove-mentioned drawbacks, in particular which provides more comfort andimproved quality perception. It is also an object of the presentdisclosure to provide a personal care implement comprising such handleand a head.

SUMMARY OF THE INVENTION

In accordance with one aspect, a handle for a personal care implement isprovided, the handle comprising a connector for repeatedly attaching anddetaching a head to and from the handle, the handle having alongitudinal extension extending between a proximal end closest to thehead and a distal end, the distal end being opposite the proximal end,the handle further comprising:

-   -   a core structure, the core structure and the connector being        unitarily made to form a core-connector unit, and    -   a second component at least partially covering the core        structure, wherein        the core structure has a longitudinal extension extending along        the longitudinal extension of the handle, the core structure        comprising at least two protrusions interlocking with the second        component.

In accordance with one aspect, a personal care implement is provided,the personal care implement comprising such handle and a head.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is described in more detail below with reference tovarious embodiments and figures, wherein:

FIG. 1 shows an example embodiment of personal care implement accordingto the present disclosure, the implement comprising a head and a handle,the handle (shown in cross-sectional view along A-A) comprising acore-connector unit, a second component, a third component and aspring-loaded snap element;

FIG. 2 shows a perspective view of the core-connector unit of the handleof FIG. 1;

FIG. 3 shows a cross-sectional view along B-B of the handle of FIG. 1;

FIG. 4 shows a perspective view of the handle of FIG. 1 without thethird component, and the spring-loaded snap element;

FIG. 5 shows a perspective view of the handle of FIG. 1 without thespring-loaded snap element;

FIG. 6 shows a perspective view of the handle of FIG. 1, with thespring-loaded snap element in exploded view;

FIG. 7 shows the connector of the core-connector unit of FIG. 2; and

FIG. 8 shows the method steps for manufacturing the handle of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

A handle for a personal care implement according to the presentdisclosure comprises a connector for repeatedly attaching and detachinga head to and from the handle. The connector may comprise a snap-fitlocking mechanism, e.g. a spring-loaded ball element, for securelyattaching the head to the handle, and for providing sufficiently strongconnection and stability between the head and the handle to enable auser to perform, e.g. a brushing action.

The personal care implement according to the present disclosure may beany type of personal care implement, e.g. a wet shaving razor, or anoral care implement, preferably a toothbrush, e.g. a manual toothbrush.The head may be any type of replaceable refill, e.g. a razor cartridgeor an oral-care refill, including but not limited to brush-head refills,interdental or toothpick refills, tongue/tissue-cleaner refills, andchemistry-applicator refills. A brush head may comprise at least onetooth cleaning element, e.g. a tuft of bristles and/or an elastomericelement, fixed to a mounting surface of the head.

According to the present disclosure, the connector is unitarily madewith a core structure and forms with the core structure a core-connectorunit, i.e. said unit is formed as one piece which cannot be separatedwithout destroying the unit. Since the connector and the core structureare made as one unitary piece, e.g. in a single injection molding step,manufacturing can be simplified, and production costs reduced.

The core structure is at least partially covered by a second componentto form a handle body to be gripped by a user. In other words, the corestructure is at least partially embedded in another handle material.While the core-connector unit provides the handle with a skeleton,reinforcing brace or stiffening girder, the second component can providethe handle or handle body with certain and superior haptics enablingeasy and comfortable use of the handle.

The handle has a longitudinal extension extending between a proximal endclosest to the head and a distal end, the distal end being opposite theproximal end. The core structure has a longitudinal extension extendingalong the longitudinal extension of the handle. At least two protrusionsextend from length extension of the core structure and interlock withthe second component to provide a robust handle body. The core-connectorunit and the second component can be well-connected my means of theprotrusions, and are not separable under normal use conditions.

The at least two protrusions may extend from the length extension of thecore structure in a substantially orthogonal/perpendicular direction.Such protrusions can easily be manufactured together with the corestructure, e.g. by injection molding. The protrusions may facilitate andenable a solid connection and mechanical interlocking between the corestructure and the second component. The protrusions may have the form ofa rib, fin, bar, bridge and/or a nub.

The core structure may provide superior support and strength to thesecond component, and, thus, to the overall handle body, if the corestructure comprises a length extension extending at least 20%,preferably at least 25%, further preferably at least 50%, even morepreferably at least 75%, or at least 85% along the overall lengthextension of the handle. Such handle is less likely to get damaged or tobreak if dropped to the floor, and, thus, may ensure a longer lifetimeof the handle.

In general, personal and oral care implements, in particulartoothbrushes, comprising exchangeable heads require high quality androbust connector structures as the heads get frequently attached anddetached to and from the handle. Defects caused by wear and tear,fatigue or premature ageing are commonly known problems and may resultin low quality perception and early substitution of the product.

In order to overcome these drawbacks, the core-connector unit may bemade from a fiber-reinforced material. The fiber-reinforced material maybe a composite material made of a polymer matrix/polymer base materialreinforced with fibers. The polymer base material may be selected fromthe group of: polyamide (PA, e.g. PA6, PA66), styrene acrylonitrileresin (SAN), polybutylene terephthalate (PBT), polyethyleneterephthalate (PET), recycled plastic materials, or mixtures thereof.The polymer base material may at least partially contain recycledplastic material.

The fibers may be selected from the group of: inorganic particulates,glass fibers, carbon fibers, aramid fibers, basalt fibers, wood fibers,or any combinations thereof. Glass fibers may improve strength,elasticity and heat resistance of the polymer base material. Carbon andaramid fibers may improve elasticity, tensile and compression strengthof the polymer base material. Wood fibers may improve flexural strength,tensile modulus, and tensile strength of the polymer base material.Inorganic particulates may improve isotropic shrinkage, abrasion andcompression strength of the polymer base material.

The fiber-reinforced material may comprise from about 10 wt % to about50 wt %, or from about 25 wt % to about 35 wt %, or about 30 wt %fibers. The core-connector unit may be made from a glassfiber-reinforced polymer material comprising about 30 wt % glass fiber.The polymer material may be a polyamide or polybutylene terephthalate,polyethylene terephthalate, or a combination of polybutyleneterephthalate and polyethylene terephthalate.

The glass fibers embedded in the polymer material may providesignificantly increased stiffness, wear resistance and integrity to thepolymer material forming the core-connector unit. For personalimplements, e.g. oral care handles from which the heads are gettingfrequently detached and re-attached, such material provides theconnector with wear resistance allowing the handle to be used over alonger period of time. Long lasting connector properties are inparticular important for toothbrushes as the head and handle often getsoiled with slurry and toothpaste containing abrasive particles. If theconnector material is not sufficiently resistant against abrasives, theabrasives may grind/sand down material of the connector, therebychanging the outer geometry of the connector. As a result, the connectormay lose its function, and/or its ability to securely hold the head inplace during use, e.g. during brushing.

The fiber-reinforced material may have a density from about 1 g/cm³ toabout 1.7 g/cm³, preferably about 1.4 g/cm³.

The polymer base material may be selected from the group of: polyamide(PA, e.g. PA6, PA66), styrene acrylonitrile resin (SAN), polybutyleneterephthalate (PBT), polyethylene terephthalate (PET), recycled plasticmaterials, or mixtures thereof. The polymer base material may at leastpartially contain recycled plastic material.

Styrene acrylonitrile (SAN) as a polymer base material may provide highthermal resistance properties. The acrylonitrile units in the chainenable SAN to have a glass transition temperature greater than 100° C.The properties of SAN may allow for reduced cycle time during a moldingstep due to relatively earlier and quicker transition temperature. Byinjection molding of the fiber-reinforced material of the presentdisclosure, the temperature of the material melt is above the Tg region(viscous or rubbery condition). During cooling the compound attains thehigh Tg temperature early and reaches dimensional stability (glassycondition). Over-molding of the fiber-reinforced material is possible asthe material stays dimensional stable due to the high Tg of thematerial.

Polybutylene terephthalate (PBT) and/or polyethylene terephthalate (PET)as a polymer base material may provide the handle with high qualitysurface properties, including improved optical characteristics, and highimpact strength. Once heated, polybutylene terephthalate andpolyethylene terephthalate represent a high temperature-resistant melthaving low viscosity and a high Melt Flow Index (MFI). Therefore,processability of the fiber-reinforced material during molding may beimproved.

Polyamide (PA) is defined as a polymer with repeating units linked byamide bonds. Polyamides exhibit high durability and strength. Forexample, polycaprolactam (PA6) and nylon6-6 (PA66) possess high tensilestrength, rigidity, good stability under head as well as elasticity andlustre. PA6 and PA66 are highly resistant to abrasion and chemicals suchas acids and alkalis. PA6 is generally white and can be dyed prior toproduction to various colors.

The second component may be made from a polymeric material comprising apolymer base material and a filler material, preferably an inorganicfiller material. The polymer base material may be selected from thefollowing: polyamide, styrene acrylonitrile resin, polybutyleneterephthalate, polyethylene terephthalate, recycled plastic materials,or mixtures thereof. The polymer base material may at least partiallycontain recycled plastic material.

Styrene acrylonitrile (SAN) may provide high thermal resistanceproperties. The acrylonitrile units in the chain enable SAN to have aglass transition temperature greater than 100° C. The properties of SANmay allow for reduced cycle time during a molding step due to relativelyearlier and quicker transition temperature. Amorphous polymers aresuitable for heavy resin materials of the present disclosure due to theglass transition temperature Tg at which an amorphous polymer istransformed, in a reversible way, from a viscous or rubbery condition toa hard one. By injection molding of the fiber-reinforced material of thepresent disclosure, the temperature of the material melt is above the Tgregion (viscous or rubbery condition). During cooling the compoundattains the high Tg temperature early and reaches dimensional stability(glassy condition). Over-molding of the fiber-reinforced material ispossible as the material stays dimensional stable due to the high Tg ofthe material.

Polybutylene terephthalate (PBT) and/or polyethylene terephthalate (PET)may provide the handle with high quality surface properties, includingimproved optical characteristics, and high impact strength. Once heated,polybutylene terephthalate and polyethylene terephthalate represent ahigh temperature-resistant melt having low viscosity and a high MeltFlow Index (MFI). Therefore, processability of the fiber-reinforcedmaterial during molding may be improved.

Polyamide (PA) is defined as a polymer with repeating units linked byamide bonds. Polyamides exhibit high durability and strength. Forexample, polycaprolactam (PA6) and nylon6-6 (PA66) possess high tensilestrength, rigidity, good stability under head as well as elasticity andlustre. PA6 and PA66 are highly resistant to abrasion and chemicals suchas acids and alkalis. PA6 is generally white and can be dyed prior toproduction to various colors.

The filler material may be selected from the group of: zinc oxide, ironoxide, barium sulfate, titanium dioxide, aluminium oxide, or anycombinations thereof. The filler material may constitute from about 50wt % to about 80 wt % of the polymeric material. Zinc oxide, iron oxide,barium sulfate and titanium dioxide have a density of at least 4 g/cm³,and may, thus, provide the polymeric material forming the secondcomponent with a relatively heavy weight. Further, a relatively highthermal conductivity of the second component can be provided if zincoxide and/or aluminium oxide is used as a filler material.

In case zinc oxide is used as a filler material having a substantiallywhite/light color, the second component polymer base material can becolored with any type of dye. Instead of applying an additional coating,e.g., by electroplating and/or lacquering the second component with acolor coating (which would be required if a black/dark filler materialwas used, e.g., iron oxide), dye master batches can simply be added tothe base material/second component material.

The polymeric material of the second component may have a relativelyhigh density from about 2 g/cm³ to about 3.5 g/cm³, preferably about 2.7g/cm³, which is significantly higher than the density of commonly usedplastic handle materials. A density of about 2.7 g/cm³ may be providedby a polymeric material comprising an inorganic filler material and apolymer base material, wherein the polymer base material may bepolyamide, and wherein the inorganic filler material may be zinc oxideconstituting from about 70 wt % to about 75 wt % of the polymericmaterial.

With a density from about 2 g/cm³ to about 3.5 g/cm³, preferably about2.7 g/cm³, the second component is significantly heavier and provides adifferent haptic impression to consumers during use of the handle ascompared to commonly used handle materials, e.g. polypropylene having adensity of about 0.9 g/cm³ only. As the weight of the handle materialmay be relatively high, this may provide a user with high-qualityperception and comfortable feeling during use of the personal careimplement. Usually, users are accustomed that products, in particular inthe personal care sector, have a specific weight that guarantees highproduct quality and provides comfortable feeling during use of theproduct. Consequently, the handle for the personal care implementaccording to the present disclosure may provide such superior productquality perception.

By using different materials for the core-connector unit and the secondcomponent, respectively, the handle properties can be improved withregards to different aspects at the same time. The second componentwhich may comprise a relatively high amount of filler material (e.g. atleast 50 wt %) provides the overall handle with a high specific weight,as well as with higher heat conductivity and heat capacity as comparedto handles made from e.g. polypropylene. Thus, the handle according tothe present disclosure can be perceived as a premium handle versushandles made from standard plastic materials. Height weight/lowertemperature are typically attributes that are linked to materials likemetal or ceramic, that typically represents a higher level of qualityand price point.

However, on the other side, materials with high amount of fillermaterial are more brittle than standard plastic materials, and, thus,can break more easily, e.g. if the handle is dropped to the ground, orhits against a hard object. Surprisingly, it has been found out that thecore structure according to the present disclosure may compensate forthe brittle characteristics of the second component if the corestructure comprises a length extension extending at least 20%,preferably at least 25%, further preferably at least 50%, even morepreferably at least 75%, or at least 85% along the overall lengthextension of the handle. By adding fibers, e.g. glass fibers, to thepolymer base material, the properties of the polymer base material isimproved with regards to strength, elasticity and heat resistance.According to the present disclosure, the fiber-reinforced materialforming the core structure can compensate for the increased brittlenessof the polymeric material of the second component and may ensureintegrity of the product over lifetime, e.g. when the handle is droppedto the floor.

Also, by forming the connector together with the core structure, solidattachment of the head to the handle can be ensured, as well. As notonly the core structure, but also the connector may be formed from thefiber-reinforced material, the fit of the head onto the connector of thehandle may less likely wear out over the life time of the personal careimplement, thereby providing not only a high quality consumer product,but also a more sustainable, and eco-friendly personal care implement.

Further, the combination of the specifically chosen materials used forthe core-connector unit and the second component allows for simpleovermolding of the core structure with the polymeric material of thesecond component without the need for complex assembly steps.

A circular collar/ring may be unitarily formed with the core-connectorunit, e.g. in one injection molding step. The collar/ring may beprovided at the intersection between the connector and the corestructure. Such collar/ring may ensure a tight connection between thecore-connector unit and the second component. When molding the secondcomponent material onto the core structure, the material of the secondcomponent shrinks to some extent, and consequently provides a press fitbetween the core-connector unit and the second component which ensures asecure and tight connection between the core-connector unit and thesecond component. Since the collar is provided at the intersectionbetween the connector and the core structure, the collar can form asupport/contact area for the second component.

The collar/ring may comprise a step or recess provided in the area beingin direct contact with the second component. When the step provided inthe outer geometry of the collar gets overmolded by the material formingthe second component, a very tight fitting between the core-connectorunit and the second component can be provided. Such tight fitting mayeliminate any deep gaps between the core-connector unit and the secondcomponent, in which toothpaste slurry could accumulate otherwise,thereby rending the handle more hygienic. The step may have relativelysmall dimensions, e.g. a height from about 0.5 mm to about 1.5 mm,thereby still providing the benefits of a tight fit. If the height ofthe step is relatively small (e.g. from about 0.5 mm to about 1.5 mm)the layer of the second component material covering the step may beaccordingly relatively thin, i.e. from about 0.5 mm to about 1.5 mm.

The press fit according to the present disclose may also be referred toas interference fit, or shrink fit, and is a form of fastening betweentwo tight fitting mating parts that produces a joint which is heldtogether also by friction after the parts are pushed together. A pressfit or shrink fit allows the components to be joined without applyingexternal force; the press fit/shrink fit is provided automatically by arelative size change after molding when the second component returns tonormal room temperature. By heating the material of the second componentto allow molding onto the core-connector unit, and by letting thematerial to return to ambient/room temperature a tight shrink fitbetween the core-connector unit and the second component can beprovided. Such tight mechanical connection, i.e. a tight pressfit/shrink fit according to the present disclosure may also enable theuse of handle materials (for the core-connector unit and the secondcomponent, respectively) which do not form a chemical bond aftermolding.

The collar may abut and, thus, may be in direct contact with the secondcomponent which at least partially covers the core structure to providean even tighter connection. Further, the collar may be substantiallyflush with the second component, and may provide an even outer lateralsurface of the handle body without creating any gaps or edges in whichpaste and slurry could accumulate. Thus, such handle provides superiorhaptics, and renders the personal care implement more hygienic.

To provide improved gripping properties of the handle, a thirdcomponent, e.g. a thermoplastic elastomer material (TPE) and/or apolypropylene material, may be overmolded onto the core structure and/orthe second component. The third component may provide gripping area(s)on the outer surface of the handle.

For example, the handle may comprise a thumb rest being made from thethird component, e.g. a thermoplastic elastomer material and/or apolypropylene material. These materials can be easily injection moldedover the core structure and/or the second component as discussed above.Such thumb rest may provide the handle of the personal care implementwith improved handling properties, e.g. with anti-slip properties toimprove the maneuverability of the personal care implement under wetconditions, e.g. when the user brushes teeth. The thumb rest may be madefrom thermoplastic elastomer having a Shore A hardness from about 30 toabout 60, or about 40 to prevent the oral care implement from being tooslippery when used in wet conditions. At least a portion of the thumbrest may have a concave shape with an angle α with respect to the areaof the remaining portion of the thumb rest from about 20° to about 25°,or about 24°. Alternatively, the thumb rest may be an elongated stripextending along the length extensions of the handle. The thumb rest or agripping region may be attached onto the front surface of the handle inthe region close to the proximal end, i.e. closest to the head. Thethumb rest may comprise a plurality of ribs extending substantiallyperpendicular and/or diagonal to the longitudinal axis of the handle.Such ribs may allow users/consumers to use the personal care implementwith even more control. The user/consumer can better grasp andmanipulate the handle during use. Such handle may provide furtherimproved control and greater comfort during use (e.g. tooth brushing),in particular under wet conditions.

The third component may not only form the thumb rest on the frontsurface of the handle, but also a palm grip on the back surface beingopposite the front surface to be gripped by the user's/consumer'sfingers and thumb. Such handle configuration may even further resistslippage during use. The third component material (e.g. TPE) may extendthrough an aperture provided in the underlying second component and/orcore structure.

A method for manufacturing a handle for a personal care implement maycomprise the following steps:

-   -   molding a core-connector unit from a fiber-reinforced material,        the core-connector unit comprising a core structure and a        connector for attaching a head to the handle, the connector        comprising a cavity,    -   at least partially overmolding the core-connector unit with a        polymeric material to form a second component, the polymeric        material comprising a filler material,    -   at least partially overmolding the core-connector unit and/or        the second component with a material to form a third component,        preferably a thermoplastic elastomer, to form a grip portion of        the handle,    -   inserting a snap-fit element into the cavity of the connector.

The snap-fit element may be a spring-loaded ball element. To this end, aspring, a ball and a cap holding the compressed spring and ball in placemay be inserted into the cavity of the connector. The cap may be fixedin the cavity by e.g. press fitting and/or ultrasonic welding. The capmay be made from the fiber-reinforced material according to the presentdisclosure or from a different material, e.g. metal.

A part of the core structure may remain visible at the outside of thehandle, e.g. to provide additional color contrasting structuresimproving the aesthetical appearance of the handle. For example, an areaexhibiting a logo can be provided by a part of the core structureexcluded from overmolding, and, thus, remaining visible.

The handle according to the present disclosure may comprise from about 5wt % to about 20 wt % of fiber-reinforced material forming thecore-connector unit, from about 70 wt % to about 95 wt % of a polymericmaterial comprising a filler and forming the second component, and fromabout 1 wt % to about 10 wt % of a third component material, preferablya thermoplastic elastomer, to form a grip portion of the handle.

The handle according to the present disclosure may comprise from about13 wt % to about 18 wt % of fiber-reinforced material forming thecore-connector unit, from about 75 wt % to about 85 wt % of a polymericmaterial comprising a filler and forming the second component, and fromabout 2 wt % to about 5 wt % of a third component material, preferably athermoplastic elastomer, to form a grip portion of the handle.

Since the material of the handle (material of the core-connectorstructure and of the second component) may have a higher density thanthe material of the head (e.g. made from polypropylene), the center ofmass/center of gravity lies within the handle (even if the brush head isloaded with toothpaste) which enables users to perform awell-coordinated brushing technique with improved sensory feeling duringbrushing. The center of gravity provided in the center of the handleprovides an oral care implement which is better balanced and does nottip over/does not get head loaded once toothpaste is applied onto thebrush head. Further, when users apply the different grip styles/brushingtechniques, the oral care implement according to the present disclosurehas the advantage that the center of gravity is in or very close to thepivot point of the wrist joint. A balanced toothbrush is easier tocontrol in the mouth, thereby allowing more precise and accuratebrushing movements which enables better cleaning.

While the high quality and relatively expensive handle of the personalcare implement is adapted for use over a longer period of time ascompared to common implements, e g manual toothbrushes which arediscarded after about three months of use, the relatively cheap refillcan be exchanged on a regular basis, e.g. after about three months. Thisprovides a cost-efficient and environmentally sustainable high qualitypersonal/oral care implement.

Further, as the polymeric material of the second component may comprisea relatively high amount of filler material which may be pre-mixed withat least a portion of the base material, such polymeric material mayallow for control of the weight of the handle in whatever location, e.g.by filler variation. Control of the overall personal care implement maybe beneficially due to the relatively high weight of the handle. It isnow possible to use the mass/weight distribution of the polymericmaterial for adaption of the inertial moment of the finished handle.

As discussed above, the head of the personal care implement can beattached to the handle via the connector comprising a snap-fitelement/snap-fit locking mechanism to ensure sufficiently strongconnection and stability between the head and the handle, e.g. to enablea user to perform a brushing action. The connector may have an outerlateral surface and a recess therein, the recess forming a cavity withinthe connector. Within the cavity a spring-loaded ball element may beprovided. The spring-loaded ball element may comprise a ball and aspring, the spring applying a radial force onto the ball in a directiontowards the outer lateral surface of the connector. In the following aradial force is defined by a force applied in a direction beingsubstantially perpendicular to the longitudinal length extension of theconnector. The spring applies a force onto the ball and pushes the balloutwards so that the ball extends slightly beyond the outer lateralsurface of the connector. An inner wall of a hollow portion provided inthe head may comprise a recess for receiving the ball of thespring-loaded ball element. Once the head is snap-fitted onto theconnector, the head is fixed on the handle/connector in an axialdirection. In other words, the connector allows for easyattachment/detachment of the head to and from the handle. A user canattach the head to the handle by a simple linear motion. Further, theball-snap may provide a precise fixation of the head, and a distincthaptic feedback may be given to the user that the head is snapped-onsecurely. In other words, the user may recognize once the ball engagesinto the recess provided in the inner wall of the hollow portion of thehead. The brush head can be easily removed, i.e. without performing asynchronized action with other elements/unlocking mechanisms.

The head can be fixed on the handle until a specific/predeterminedpull-off force is applied. The connection between the head and connectoris sufficiently strong enabling well-coordinated brushing techniques.The head does not get loosened from the handle and does not twist asideduring use, e.g. brushing.

The ball and/or the spring of the spring-loaded ball element may be madefrom stainless steel. While typical snap elements comprise a springelement made from plastic that shows relaxation and aging effects overtime, a stainless steel spring shows a constant spring rate over time,also under extended use conditions (e.g. temperature). A spring-loadedball element made from stainless steel may provide long-lasting,reliable fixation of the head on the connector/handle.

The connector may comprise a first substantially cylindrical section anda second substantially cylindrical section, wherein the first and thesecond cylindrical sections may be connected by an at least partiallyconically shaped section. The first substantially cylindrical section,the at least partially conically shaped section and the secondsubstantially cylindrical section may be arranged in consecutive orderand may define a longitudinal length extension of the connector. Thefirst and the second substantially cylindrical sections may be placedoff-center with respect to the longitudinal length extension of theconnector.

In the following, a substantially cylindrical section is defined by athree-dimensional body having a longitudinal length extension and across-sectional area extending substantially perpendicular to thelongitudinal length extension. The cross-sectional area has a shapebeing substantially constant along the longitudinal length extension.Since the connector may be manufactured by an injection molding process,a substantially cylindrical section also comprises sections/bodies whichhave a slight draft angle of up to 2°. In other words, a substantiallycylindrical section also comprises a section/body which tapers slightlyby up to 2° towards a proximal end which is closest to the head once thehead is attached to the connector.

The cross-sectional area may have any shape, for example substantiallycircular, ellipsoid, rectangular, semi-circular, circular with aflattening portion, convex or concave. The cross-sectional area may havethe shape of a polygon, for example of a square or triangle. The outerlateral surface circumventing the cylinder along its length extensioncan be defined as being composed of straight lines which aresubstantially parallel with respect to the longitudinal length extensionof the cylinder.

The head of the oral care implement has a distal end and a proximal end,the proximal end being defined as the end closest to the handle. Theproximal end of the head may comprise a hollow portion for receiving apart of the connector, for example, the second substantially cylindricalsection, the at least partially conically shaped section and a part ofthe first substantially cylindrical section. The hollow portion of thehead may have an inner wall with a geometry/contour which corresponds tothe outer geometry/contour of the part of the connector to be insertedinto the hollow portion of the head. The eccentricarrangement/off-center positioning of the substantially cylindricalsections of the connector enables precise positioning of the brush headon the handle. The geometric position of the head can be clearlydefined. As the handle comprises the connector at a proximal end beingclosest to the head, the eccentric/off-center arrangement of the twosubstantially cylindrical sections may act as a guidance element when auser attaches the head to the handle. In other words, the twosubstantially cylindrical sections may allow for accurate fittingbetween the head and the handle. Further, the eccentric/off-centerarrangement of the two substantially cylindrical sections may provide ananti-twist protection for the head on the handle during brushing, forexample if a lateral force is applied onto the head.

The first substantially cylindrical section and the second substantiallycylindrical section have a length extension and a cross-sectional areaextending substantially perpendicular to the length extension, and thecross-sectional area of the first substantially cylindrical sectionand/or second of the second substantially cylindrical section may besubstantially circular. Such geometry provides a robust and simplestructure which is easy to clean after usage of the oral care implement.Further, since the outer geometry is relatively simple, such connectorcan be manufactured in a cost-efficient manner.

The first substantially cylindrical section may have a cross-sectionalarea being greater than the cross-sectional area of the secondsubstantially cylindrical section. For example, the first substantiallycylindrical section to be inserted into a hollow portion at the proximalend of the handle, may have a substantially circular cross-sectionalarea with a diameter of about 8 mm to about 10 mm, preferably about 9mm, while the second substantially cylindrical section to be insertedinto a hollow portion at the proximal end of the head, may have asubstantially circular cross-sectional area with a diameter of about 4mm to about 6 mm, preferably about 5 mm.

The first and the second substantially cylindrical sections may have afirst and a second longitudinal central axis, respectively which aredefined as the symmetry axis of the first and the second substantiallycylindrical sections. The first and the second substantially cylindricalsections may be placed/arranged with respect to each other so that thesecond longitudinal central axis of the second cylindrical section islocated off-center with respect to the first longitudinal central axisof the first cylindrical section by about 1 mm to about 2.5 mm, or byabout 1.5 mm to about 2 mm, or by about 1.65 mm. In other words, thecenter of the second substantially cylindrical section isoffset/eccentric from the longitudinal central axis of the firstsubstantially cylindrical section by a distance of about 1 mm to about2.5 mm, or of about 1.5 mm to about 2 mm, or of about 1.65 mm.

Such connector may be easy to manufacture, e.g. by injection molding,and provides sufficient torsional stability for the oral care implementif lateral forces are applied onto the brush head.

The first and/or the second substantially cylindrical section maycomprise a flattening portion extending along the length extension ofthe first and/or second substantially cylindrical section. Suchflattening portion may provide the personal care implement (e.g.toothbrush) with additional anti-twist protection for the head beingconnected to the handle during use (e.g. brushing), for example if alateral force is applied onto the head.

The first and the second substantially cylindrical sections may have afirst and a second outer surface, respectively, and the first and thesecond substantially cylindrical sections may be arranged with respectto each other so that a part of the first outer surface and a part thesecond outer surfaces are substantially in straight alignment. Theflattening portion, optionally comprising the spring-loaded ballelement, may be arranged opposite the first and second outer surfacesbeing substantially in straight alignment. Such connector has an easy toclean outer geometry. The connector is robust, easy to use, and can bemanufactured in a cost-efficient manner.

The proximal end of the handle (e.g. the ring/collar provided at theintersection between the connector and core structure) may comprise achamfered surface. Such chamfered surface may provide the oral careimplement with additional anti-twist protection during use. Thechamfered surface and a cross-sectional area of the handle may define anangle α from about 15° to about 30°, or from about 18° to about 28°, orabout 25°. Said cross-sectional area is defined by an area extendssubstantially perpendicular to the longitudinal length extension of thehandle. Surprisingly, it has been found out that such angled/chamferedsurface provides superior anti-twist protection. Furthermore, theangled/chamfered surface allows for draining-off fluids, like toothpasteslurry and saliva, after use of the oral care implement, therebypreventing accumulation of such fluids over time.

The connector allows for easy attachment/detachment of the head to andfrom the handle. The user can attach the head to the handle by a simplelinear motion. With the specific design of the substantially cylindricalsections being arranged off-center, and the chamfered surface of thehandle, the head is turned into the right orientation automaticallyduring the attachment motion (within certain tolerances). Therefore, theconsumer is not forced to precisely position the head on the handlebefore snapping it on. Further, the ball-snap provides a precisefixation of the brush head, and a distinct haptic feedback is given tothe consumer that the head is snapped-on securely. The brush head can beeasily removed, without any synchronized action with other elements(unlocking mechanisms). In addition, the connector can be cleanedeasily. The specific design of the connector may not have any recessesin which dirt, toothpaste and/or saliva accumulate. The connector mayalso avoid any fragile structures by comprising substantially roundedges, only, which may prevent easy breakage or damage of the surfaces.

To allow sufficiently good fitting of the brush head on the connector ifproduction tolerances occur, the inner wall of the hollow portion of thehead may comprise at least one rip, or two rips being arranged oppositeeach other, for precisely adjusting the head on the connector/handle.Furthermore, the at least one rip may prevent compression of air in thehollow portion of the head which could act like a spring or asadditional resistance while snapping the head on the connector/handle.

The personal care implement may be an oral care implement, in particulara toothbrush comprising a handle and a toothbrush head with toothcleaning elements.

The tooth cleaning elements of the oral care implement, e.g. bundle offilaments forming one or a plurality of tufts, may be attached to thehead by means of a hot tufting process. One method of manufacturing thehead with tufts of filaments embedded in the head may comprise thefollowing steps: In a first step, tufts are formed by providing adesired amount of filaments. In a second step, the tufts are placed intoa mold cavity so that ends of the filaments which are supposed to beattached to the head extend into said cavity. The opposite ends of thefilaments not extending into said cavity may be either end-rounded ornon-end-rounded. For example, the filaments may be not end-rounded incase the filaments are tapered filaments having a pointed tip. In athird step the head is formed around the ends of the filaments extendinginto the mold cavity by an injection molding process, thereby anchoringthe tufts in the head. Alternatively, the tufts may be anchored byforming a first part of the head—a so called “sealplate”—around the endsof the filaments extending into the mold cavity by an injection moldingprocess before the remaining part of the oral care implement is formed.Before starting the injection molding process the ends of the tuftsextending into the mold cavity may be optionally melted or fusion-bondedto join the filaments together in a fused mass or ball so that the fusedmasses or balls are located within the cavity. The tufts may be held inthe mold cavity by a mold bar having blind holes that correspond to thedesired position of the tufts on the finished head of the oral careimplement. In other words, the tufts attached to the head by means of ahot tufting process are not doubled over a middle portion along theirlength and are not mounted in the head by using an anchor/staple. Thetufts are mounted on the head by means of an anchor-free tuftingprocess.

Alternatively, the head for the oral care implement may be provided witha bristle carrier having at least one tuft hole, e.g. a blind-end bore.A tuft comprising a plurality of filaments may be fixed/anchored in saidtuft hole by a stapling process/anchor tufting method. This means, thatthe filaments of the tuft are bent/folded around an anchor, e.g. ananchor wire or anchor plate, for example made of metal, in asubstantially U-shaped manner. The filaments together with the anchorare pushed into the tuft hole so that the anchor penetrates intoopposing side walls of the tuft hole thereby anchoring/fixing/fasteningthe filaments to the bristle carrier. The anchor may be fixed inopposing side walls by positive and frictional engagement. In case thetuft hole is a blind-end bore, the anchor holds the filaments against abottom of the bore. In other words, the anchor may lie over the U-shapedbend in a substantially perpendicular manner Since the filaments of thetuft are bent around the anchor in a substantially U-shapedconfiguration, a first limb and a second limb of each filament extendfrom the bristle carrier in a filament direction.

Filament types which can be used/are suitable for usage in a staplingprocess are also called “two-sided filaments”. Heads for oral careimplements which are manufactured by a stapling process can be providedin a relatively low-cost and time-efficient manner.

The following is a non-limiting discussion of example embodiments ofpersonal care implements and parts thereof in accordance with thepresent disclosure, where reference to the Figures is made.

FIG. 1 shows a personal care implement 10, in this specific embodiment amanual toothbrush 10. The manual toothbrush 10 comprises a handle 12 andhead 14, the head 14 being repeatedly attachable to and detachable fromthe handle 12 via a connector 16. The handle 12 may be formed by usingthe process as shown in the flow chart of FIG. 8 and as furtherexplained below.

Handle 12 comprises connector 16 unitarily made with a core structure 18to form a core-connector unit 20, a second component 22, a thirdcomponent 24 and a spring-loaded snap element 26.

The core-connector unit 20 (shown in FIG. 2 in detail) is made from afiber-reinforced material. The fiber-reinforced material is a compositematerial comprising a polymer base material and fiber. The compositematerial may comprise from about 10 wt % to about 50 wt %, preferablyfrom about 25 wt % to about 35 wt %, further preferably about 30 wt %fiber. The fibers may be selected from the group of: glass fibers,carbon fibers, aramid fibers, basalt fibers, wood fibers, or anycombinations thereof. The polymer base material may be selected from thegroup of: polyamide, styrene acrylonitrile resin, polybutyleneterephthalate, polyethylene terephthalate, recycled plastic materials,or mixtures thereof. The polymer base material may at least partiallycontain recycled plastic material. In this specific embodiment, thefiber-reinforced material may comprise polyamide as the polymer basematerial and from about 30 wt % to about 35 wt % glass fiber.

The fiber-reinforced material has a density from about 1 g/cm³ to about1.7 g/cm³, in this specific embodiment about 1.4 g/cm³.

As shown in FIGS. 3 and 4, the core structure 18 of the core-connectorunit 20 is partially embedded in/overmolded by the second component 22.

The core-connector unit 20 together with the second component 22 definethe overall length extension 28 of the handle 12. The length extension28 of the handle 12 extends from a proximal end 30 closest to the head14 to a distal end 32, the distal end 32 being opposite the proximal end30.

The second component is made from a polymeric material comprising a basematerial and a filler material, preferably an inorganic filler material,wherein the base material is selected from: polyamide, styreneacrylonitrile resin, polybutylene terephthalate, polyethyleneterephthalate, recycled plastic materials, or mixtures thereof, andwherein the filler material may constitute from about 50 wt % to about80 wt % of the polymeric material. The filler material is selected fromthe group of: zinc oxide, iron oxide, barium sulfate, titanium dioxide,aluminium oxide, or any combinations thereof. In this specificembodiment, the second component may be made from a polymeric materialcomprising polyamide as a base material and from about 60 wt % to about75 wt % zinc oxide.

The polymeric material of the second component has a density from about2 g/cm³ to about 3.5 g/cm³, in this specific embodiment about 2.7 g/cm³.

To compensate for brittle characteristics of the second component 22,the core structure 18 comprises a length extension 34 extending at least20%, preferably at least 25%, further preferably at least 50%, even morepreferably at least 75%, or at least 85% along the overall lengthextension 28 of the handle 12. In this specific embodiment, the corestructure 18 extends at least 85% along the overall length extension 28of the handle 12. By adding glass fibers to the polymer base material,the properties of the polymer base is improved with regards to strength,elasticity and heat resistance.

The core structure 18 further comprise a plurality of protrusions 36extending from the length extension 34 of the core structure 18 in asubstantially orthogonal direction. The protrusions 36 facilitate andenable a solid connection and mechanical interlocking between the corestructure 18 and the second component 22. The protrusions may have theform of a rib, fin, bar, bridge and/or a nub (see FIGS. 2 and 3).

The connector 16 of the core-connector unit 20 further comprises aring/collar 38 at the intersection 40 to the core structure 18 to ensurea tight connection between the core-connector unit 20 and the secondcomponent 22 (see FIGS. 2 and 7). The collar/ring 38 comprise a step 39or recess 38 provided in the area being in direct contact with thesecond component 22. When the step/recess 39 provided in the outergeometry of the collar 38 gets overmolded by the material forming thesecond component 22, a very tight fitting between the core-connectorunit 20 and the second component 22 can be provided. Such tight fittingmay eliminate any gaps between the core-connector unit 20 and the secondcomponent 22, in which toothpaste slurry could accumulate otherwise,thereby rending the handle more hygienic. The step 39 may haverelatively small dimensions, e.g. a height 41 from about 0.5 mm to about1.5 mm, thereby still providing the benefits of a tight fit. If theheight 41 of the step is relatively small (e.g. from about 0.5 mm toabout 1.5 mm) the layer 42 of the second component material covering thestep/recess 39 may be accordingly relatively thin, i.e. from about 0.5mm to about 1.5 mm. When molding the second component material 22 ontothe core structure 18, the material of the second component shrinks tosome extent. Consequently, a press fit between the core structure 18 andthe second component 22 is provided which ensures a secure connectionbetween the core-connector unit 20 and the second component 22.

To provide improved gripping properties of the handle 12, the thirdcomponent 24, e.g. a thermoplastic elastomer material (TPE) and/or apolypropylene material, may be overmolded onto the core structure 18and/or the second component 22. The third component 24 provides agripping area 44 on the outer surface 46 of the handle 12 (see FIGS. 5and 6). In this specific embodiment, an elongated strip 48 of TPEmaterial is provided on the front surface 50 of the handle 12.

FIG. 8 illustrates the method steps for manufacturing the handle 12 forthe personal care implement 10:

In a first step 100, a core-connector unit 20 is molded, preferablyinjection-molded, from a fiber-reinforced material, the core-connectorunit 20 comprising a core structure 18 and a connector 16 for attachinga head 14 to the handle 12, the connector 16 comprising a cavity 52.

In a second step 200, the core-connector unit 20 is at least partiallyovermolded, preferably injection-molded, with a polymeric material toform a second component 22, the polymeric material comprising a fillermaterial.

In a third step 300, the core-connector unit 20 and/or the secondcomponent 22 is at least partially overmolded, preferablyinjection-molded, with a material to form a third component 24,preferably a thermoplastic elastomer, to form a grip portion or agripping area 44 of the handle 12.

In a fourth step 400, a snap-fit element 26 is inserted into the cavity52 of the connector 16. The snap-fit element 26 may be a spring-loadedball element. To this end, a spring 54, a ball 56 and a cap 58 holdingthe compressed spring 54 and ball 56 in place may be inserted into thecavity 52 of the connector 16. The cap 58 may be fixed in the cavity 52by e.g. press fitting and/or ultrasonic welding. The cap 58 may be madefrom the fiber-reinforced material according to the present disclosureor from a different material, e.g. metal.

In the context of this disclosure, the term “substantially” refers to anarrangement of elements or features that, while in theory would beexpected to exhibit exact correspondence or behavior, may, in practiceembody something slightly less than exact. As such, the term denotes thedegree by which a quantitative value, measurement or other relatedrepresentation may vary from a stated reference without resulting in achange in the basic function of the subject matter at issue.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”

What is claimed is:
 1. A handle (12) for a personal care implement (10),the handle (12) comprising a connector (16) for repeatedly attaching anddetaching a head (14) to and from the handle (12), the handle (12)having a longitudinal extension (28) extending between a proximal end(30) closest to the head (14) and a distal end (32) opposite to theproximal end (30), the handle (12) further comprising: a core structure(18), the core structure (18) and the connector (16) being unitarilymade to form a core-connector unit (20), and a second component (22) atleast partially covering the core structure (18), wherein the corestructure (18) has a longitudinal extension (34) extending along thelongitudinal extension (28) of the handle (12), the core structure (18)comprising at least two protrusions (36) interlocking with the secondcomponent (22).
 2. The handle (12) of claim 1, wherein the at least twoprotrusions (36) extend from the length extension (34) of the corestructure (18) in a substantially perpendicular manner.
 3. The handle(12) of claim 1, wherein each of the at least two protrusions (36) formsa structure selected from the group consisting of a rib, a fin, a bar, abridge, and a nub.
 4. The handle (12) of claim 1, wherein the corestructure (18) extends at least 20% along the length extension (28) ofthe handle (12).
 5. The handle (12) of claim 1, wherein thecore-connector unit (20) is made from a fiber-reinforced material. 6.The handle (12) of claim 5, wherein the fiber-reinforced materialcomprises from about 10 wt % to about 50 wt % of fiber.
 7. The handle(12) of claim 5, wherein the fiber is selected from the group consistingof glass fibers, carbon fibers, aramid fibers, basalt fibers, woodfibers, and any combination thereof.
 8. The handle (12) of claim 5,wherein the fiber-reinforced material is a composite material comprisinga polymer base material.
 9. The handle (12) of claim 1, wherein thesecond component (22) comprises polymeric material including a polymerbase material and an inorganic filler material.
 10. The handle (12) ofclaim 7, wherein the polymer base material of at least one of thecore-connector unit and the second component is selected from the groupconsisting of polyamide, styrene acrylonitrile resin, polybutyleneterephthalate, polyethylene terephthalate, recycled plastic materials,and any combination thereof.
 11. The handle (12) of claim 9, wherein thefiller material is selected from the group consisting of zinc oxide,iron oxide, barium sulfate, titanium dioxide, aluminium oxide, and anycombination thereof.
 12. The handle (12) of claim 8, wherein the fillermaterial constitutes from about 50 wt % to about 80 wt % of thepolymeric material.
 13. The handle (12) of claim 5, wherein thefiber-reinforced material has a density of from about 1 g/cm³ to about1.7 g/cm³.
 14. The handle (12) of claim 9, wherein the polymericmaterial of the second component (22) has a density of from about 2g/cm³ to about 3.5 g/cm³.
 15. A personal care implement (10) comprisingthe handle (12) of claim 1 and a head (14).
 16. The handle (12) of claim4, wherein the core structure (18) extends at least 25% along the lengthextension (28) of the handle (12).
 17. The handle (12) of claim 16,wherein the core structure (18) extends at least 50% along the lengthextension (28) of the handle (12).
 18. The handle (12) of claim 17,wherein the core structure (18) extends at least 75% along the lengthextension (28) of the handle (12).
 19. The handle (12) of claim 18,wherein the core structure (18) extends at least 85% along the lengthextension (28) of the handle (12).
 20. The handle (12) of claim 6,wherein the fiber-reinforced material comprises from about 25 wt % toabout 35 wt % of fiber.